Additive manufacturing systems and methods for non-planar interfaces between layers

Abstract

Three-dimensional printing methods and systems use a derived geometry and aligns anisotropic inclusions in any orientation at any number of discrete volumetric sections. Structural, thermal, or geometry-based analyses are combined with inclusion alignment computations and print preparation methods and provided to 3D printers to produce composite material parts that meet demanding geometric needs as well as enhanced structural and thermal requirements. In one example, optimal inclusion alignment vectors associated with a section of the object are calculated based on specifications for the object, segmenting a three-dimensional model of the object into layer slices, grouping each section within each layer slice having similar alignment vectors and combining the groupings and generating printing instructions for the object according to the grouped alignment vectors.

The invention claimed is: 
     
       1. A method for additive manufacturing of an object, the method comprising:
 receiving, at a computer processor, a specification file describing the object as a three-dimensional model, the three-dimensional model comprising a plurality of layer slices of the object; 
 defining, by the computer processor, a three-dimensional geometric interface between layer slices that provides for a three-dimensional patterned, non-planar interface between adjacent layer slices; and 
 sequentially printing the layer slices including the non-planar interfaces using an additive manufacturing apparatus thereby formulating the object. 
 
     
     
       2. The method of  claim 1  wherein at least a subset of adjacent layer slices are subdivided into complementing sets of images having patterned extruded overlays. 
     
     
       3. The method of  claim 2  wherein the subdivided sets of images are defined as having a fractional layer thickness of a nominal layer height. 
     
     
       4. The method of  claim 3  wherein the fractional layer thickness is one of half of the nominal layer height, one third of the nominal layer height or one quarter of the nominal layer height. 
     
     
       5. The method of  claim 4  further comprising polymerizing each fractional layer in alternating fashion. 
     
     
       6. The method of  claim 2  wherein the patterned extruded overlay comprises one of a rhomboid or a triangular pattern. 
     
     
       7. The method of  claim 2  wherein the patterned overlay comprises an alternating stacking pattern such that the pattern repeats every n th  fractional layer, where n is a whole number. 
     
     
       8. The method of  claim 2  wherein the patterned overlay comprises an alternating stacking pattern such that the pattern repeats at most every third fractional layer. 
     
     
       9. The method of  claim 1  wherein the three-dimensional patterned non-planar interface comprises a checkerboard configuration comprising interdigitated extruded squares. 
     
     
       10. The method of  claim 9  wherein the checkerboard configuration comprises an array of extruded squares having substantially consistent dimensions along an x axis and y axis and having alternating dimensions along a z axis. 
     
     
       11. The method of  claim 1  further comprising defining a plurality of optimal inclusion alignment vectors for each fractional layer, each inclusion alignment vector being associated with a daxel of the object;
 grouping daxels within each fractional layer having substantially similar alignment vectors; 
 combining the grouped daxels into subdivided fractional layers; and 
 generating machine instructions directing a three-dimensional printer to manufacture the object such that the anisotropic inclusions are aligned according to the grouped alignment vectors. 
 
     
     
       12. The method of  claim 11  wherein the anisotropic inclusions are aligned within an X-Y plane such that the anisotropic inclusions cross at least one boundary of adjacent layer slices. 
     
     
       13. A system for additive manufacturing of an object, the system comprising:
 one or more computer processors programmed to perform operations to: 
 receive a specification file describing the object as a three-dimensional model, the three-dimensional model comprising a plurality of layer slices of the object; 
 define a three-dimensional geometric interface between layer slices that provides for a three-dimensional patterned, non-planar interface between adjacent layer slices; and 
 sequentially print the layer slices using an additive manufacturing apparatus thereby formulating the object. 
 
     
     
       14. The system of  claim 13  wherein at least a subset of adjacent layer slices are subdivided into complementing sets of images having patterned extruded overlays. 
     
     
       15. The system of  claim 14  wherein the subdivided sets of images are defined as having a fractional layer thickness of a nominal layer height. 
     
     
       16. The system of  claim 15  wherein the fractional layer thickness is one of half of the nominal layer height, one third of the nominal layer height or one quarter of the nominal layer height. 
     
     
       17. The system of  claim 16  wherein the computer processors are further programmed to perform operations to polymerize each fractional layer in alternating fashion. 
     
     
       18. The system of  claim 14  wherein the patterned extruded overlay comprises one of a rhomboid or a triangular pattern. 
     
     
       19. The system of  claim 14  wherein the patterned overlay comprises an alternating stacking pattern such that the pattern repeats every n th  fractional layer, where n is a whole number. 
     
     
       20. The system of  claim 14  wherein the patterned overlay comprises an alternating stacking pattern such that the pattern repeats at most every third fractional layer. 
     
     
       21. The system of  claim 13  wherein the three-dimensional patterned non-planar interface comprises a checkerboard configuration comprising interdigitated extruded squares. 
     
     
       22. The system of  claim 21  wherein the checkerboard configuration comprises an array of extruded squares having substantially consistent dimensions along an x axis and y axis and having alternating dimensions along a z axis. 
     
     
       23. The system of  claim 13  wherein the computer processors are further programmed to:
 define a plurality of optimal inclusion alignment vectors for each fractional layer, each inclusion alignment vector being associated with a daxel of the object; 
 group daxels within each fractional layer having substantially similar alignment vectors; 
 combine the grouped daxels into subdivided fractional layers; and 
 generate machine instructions directing a three-dimensional printer to manufacture the object such that the anisotropic inclusions are aligned according to the grouped alignment vectors. 
 
     
     
       24. The system of  claim 23  wherein the operations direct the anisotropic inclusions to be aligned within an X-Y plane such that the anisotropic inclusions cross at least one boundary of adjacent layer slices.